Futon furniture frame having a single panel of elastomeric support fabric

ABSTRACT

A futon style sofa bed, preferably made from a metal frame, and having an elastomeric material stretched to cover the frame. The elastomeric material obviates the need for support slats, as well as cushions or a mattress. In a preferred embodiment, the frame members are made from steel tubing, and the fabric is oriented within the frame so that the warp direction (the direction of primary stretch) runs from front to back or from side to side in the seat frame, and also in the seat back. Adjusting means is disclosed, for adjusting the length and/or width of the frame, thus adjusting the tension of the fabric stretched about the frame.

BACKGROUND OF THE INVENTION

[0001] Traditionally, futon sofas have consisted of a wooden or metal frame, with a foldable cushion mattress positioned within the frame. The futon mattress has generally served a dual purpose in the past, as a seat and backrest when the futon is in the upright position, as well as being a traditional mattress when the futon is in the horizontal sleeper position. Conventional futon frames typically support the mattress by using slats, wooden or metal, spanning from the front to the back in the seat bottom and from the top to bottom in the backrest. Because these slats are rigid, they frequently may be felt by the user in either position, and may cause discomfort, especially if the user is trying to sleep on the futon for extended periods. Another problem associated with traditional style futons is that they cannot be easily disassembled for purposes of moving the futon or for replacing broken supports. Further, by employing rigid supports and a mattress, maneuvering the futon between the sofa position and the bed or sleeper position may be difficult.

[0002] Therefore, it would be desirable to provide a futon frame that is more comfortable to a user, and is more easily maneuverable between the sofa and bed positions. A futon having elastomeric fabric instead of rigid slats would obviate the need for a separate mattress, making the futon less expensive to manufacture and to transport. It would also be desirable to provide a futon that could be easily assembled and disassembled, so that the futon could be more easily transported. Further, if the elastomeric support material became soiled or torn, having a frame that is easily disassembled would facilitate the removal for cleaning, repair, or replacement of the support material.

OBJECTS OF THE INVENTION

[0003] Accordingly, an important object of the present invention is to provide a futon frame structure that includes a single panel of elastomeric support fabric instead of traditional rigid slats.

[0004] Another important object of the present invention is to provide a futon frame structure that may be used comfortably without a separate mattress or cushion being employed in conjunction with the frame.

[0005] Still another important object of the present invention is to provide a futon frame structure that is inexpensive to manufacture, and which is easy to manipulate between the upright and the horizontal position.

[0006] Another important object of the present invention is to provide a method of assembling a futon frame and assembly that may be performed by an ordinary person using a minimum amount of basic tools or other equipment.

[0007] Yet another important object of the present invention is to provide an adjustable futon frame structure with elastomeric support fabric stretched over the frame, so that the tension of the fabric may be adjusted as desired.

[0008] Still another important object of the present invention is to provide a novel futon frame and structure that overcomes some of the problems associated with traditional futon structures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:

[0010]FIG. 1 is a perspective view showing an embodiment of the present invention where a rigid, pivotal frame supports an elastomeric fabric in a seating position;

[0011]FIG. 1A is a perspective view of an alternate embodiment of the present invention;

[0012]FIG. 2 is a cross-sectional view along the line 2-2 of FIG. 1, showing a connection between a straight tube and a U-shaped frame member;

[0013]FIG. 3 is a cross-sectional side view along the line 3-3 of FIG. 1, showing the longitudinal frame members disposed within the hems of the fabric;

[0014]FIG. 3A is a cross-sectional side view along the line 3-3 of FIG. 1A, where the fabric is attached to the outer frame members by means of a hem, and where the central portion of the fabric is disposed beneath the straight tube member;

[0015]FIG. 4 is a cross-sectional side view along the line 3-3 of FIG. 1, showing one step in the method of attaching the elastomeric fabric to the longitudinal portions of the frame, where the outer longitudinal members are attached first, and the middle longitudinal member is then attached while the fabric bears no tension;

[0016]FIG. 4A is a cross-sectional view showing the next step in the process illustrated in FIG. 4, wherein the upper U-shaped frame is pivoted to the horizontal position, thereby creating tension on the fabric;

[0017]FIG. 4B is a cross sectional view showing an alternate next step to be used in lieu of the next step shown in FIG. 4A, wherein the middle longitudinal member is pulled into position with a jacking screw on each end thereof;

[0018]FIG. 5 is a cross-sectional view showing an alternate method of attaching the fabric where the fabric is only attached to the two outer longitudinal frame members, and the fabric bears no tension;

[0019]FIG. 5A is a cross-sectional view showing the next step in the process illustrated in FIG. 5, where the upper U-shaped frame is positioned in the horizontal position, and the center longitudinal frame member is disposed directly above and adjacent the fabric;

[0020]FIG. 5B is a cross sectional view showing an alternate next step to be used in lieu of the next step shown in FIG. 5A, wherein the middle longitudinal member is pulled into position with a jacking screw on each end thereof;

[0021]FIG. 6 is a cross-sectional close-up view of a mechanism (in a non-extended position) for making the frame members adjustable in either a longitudinal or transverse direction, in order to adjust tension of the fabric;

[0022]FIG. 6A is a cross-sectional view of the embodiment of the frame shown in FIG. 6, showing the adjustment means in the extended position;

[0023]FIG. 7 is a perspective view of a base member in accordance with the embodiment shown in FIGS. 5, 5A and 5B;

[0024]FIG. 8 is a side view along the lines 8-8 on FIG. 7, showing a ledge and crossbar attached to a leg of an armrest member;

[0025]FIG. 9 is a complete perspective view of the embodiment of the present invention shown in FIGS. 1, 3, 4, 4A and 4B, which further includes the base member; and

[0026]FIG. 9A is a perspective view of the embodiment of the present invention shown in FIGS. 1A, 3A, 5, 5A and 5B, which further includes the base member.

DETAILED DESCRIPTION

[0027] Generally, the apparatus disclosed herein is a futon style sofa bed, preferably made from a rigid metal frame, and having an elastomeric fabric material stretched to cover the frame. This elastomeric material, which is 100% polyester in a preferred embodiment, obviates the need for support slats, as well as cushions or a mattress. It is anticipated that a non-elastic material may be used in an alternate embodiment of the present apparatus. The material may be easily installed on the frame by using a minimum amount of tools, and conversely, the material is easily removed for cleaning or replacement. In a preferred embodiment, the frame members are made from steel tubing, and the fabric is oriented within the frame so that the warp direction (the direction of primary stretch) runs longitudinally or transversely in the seat frame, and similarly in the seat back. As used herein, the term “longitudinal” shall mean the direction from one armrest to the other, and the term “transverse” shall mean the direction from the upper portion of the backrest to the lower portion thereof, and also from the front of the seat portion to the rear thereof.

[0028] Referring to FIG. 1, a first frame 4 is formed by a straight tube 6 and a fixed U-shaped frame member 8. A movable U-shaped frame member 10 is pivotally attached to the first frame 4 on both ends of the straight tube 6. The first frame 4 forms the seat of the futon, and the movable U-shaped frame member 10 forms the backrest that pivots downwardly to a horizontal position, forming a bed. A fabric 12, preferably having elastomeric qualities, is attached to the straight tube 6 and the long portions of each of the U-shaped frame members (herein, collectively called the longitudinal portions of the frame members).

[0029] The fabric 12 includes longitudinal hems 16 on both longitudinal sides or ends, and a centrally located hem 16 on an underside thereof. The longitudinal portions of the frame members are disposed within the hems 16, which act as sleeves disposed about longitudinal portions of the frame. Because the material is preferably elastomeric in nature, there exists a constant bending load on the longitudinal portions of the frame member, pulling the outer U-shaped members 8 and 10 inwardly toward the straight tube 6. The elastomeric material is stretched in the frame to between 3% and 20%, and preferably between 3% and 5%. The stretching of the material produces a force, preferably having a magnitude of about five to ten pounds per inch width (measured along the weft direction), and acting in the warp direction. Although the fabric 12 has been described as being attached to the frame members by means of hems 16, it is to be understood that any other suitable attachment means may be employed, such as hook and eyelet means, adhesion, or the like.

[0030]FIG. 1A shows an alternate embodiment, where the straight tube 6 is positioned on an upper side of the fabric, as opposed to having the fabric attached on a backside thereof by means of a hem, as shown in FIG. 1.

[0031] The straight tube 6 is crimped at either end, as shown in FIG. 2. The end of the straight tube 6 overlays the fixed U-shaped frame member 8, and a bolt 18 is passed through the assembly to secure these members in position. The protruding threaded section of the socket cap screw 19 in FIG. 2 and the mounting holes shown in FIG. 1 allow the base frame to be rigidly attached to the folding mechanism.

[0032] As seen in FIG. 3, the fabric 12 is a single layer with a hem 16 sewn at the front edge and the back edge (the longitudinal sides), and one hem 16 sewn on an underside of the fabric 12, near the center, running parallel to the two longitudinal hems 16. Each hem 16 is large enough to receive one steel tube frame member. The tubes are preferably uniform in size, and the hems 16 are preferably uniform in size, as well. An alternate embodiment is shown in FIG. 3A, where the fabric 12 only includes two hems 16, at each longitudinal side. The straight tube 6 in the center is positioned above the fabric 12 in this embodiment, and is not received by a central sleeve. As the backrest is placed in the sitting position, the straight tube 6 retains the fabric 12 in the proper position, as shown in FIG. 3A.

[0033] A method for installing the fabric 12 onto the frame includes, in a first embodiment, first attaching both longitudinal sides of the fabric 12 to the frame by sliding the hems 16 over the longitudinal frame members, like sleeves. The backrest of the futon should be in the sitting position during this step. The straight tube 6, which is unattached to the rest of the frame, is then placed within the central hem 16 of the fabric 12, as shown in FIG. 4. The backrest of the futon is then moved to the horizontal, or sleeping, position. As seen in FIG. 4A, this step stretches the fabric 12 tight, and also moves the straight tube 6 into position for attachment to the rest of the frame. This method is used for the embodiment shown in FIG. 3. Alternatively, referring to the preferred embodiment shown in FIGS. 5 and 5A, when the seat back is lowered into the sleeping position, the straight tube 6 can be attached to the rest of the frame directly above and adjacent the fabric 12, so that when the back is raised into the sitting position, the fabric 12 wraps around the straight tube 6 and maintains the prestretch. This method is used for the embodiment shown in FIG. 3A.

[0034] The stretching method shown in FIGS. 4A and 5A is preferred when the stretching tension of the fabric is relatively low, or less than about 5 pounds per inch. For higher fabric stretching tensions, greater than about 5 pounds per inch, it may be difficult to lower the seat back, so an alternate stretching method, shown in FIGS. 4B and 5B is preferred. The fabric is stretched by means of a pair of jacking screws 17, one screw attached to each end of straight tube 6, tapered washers 18, and nuts 19. The nuts 19 pull the straight tube into a position that allows it to be connected to the rest of the frame, thus stretching the fabric 12.

[0035] As shown in FIGS. 6 and 6A, an adjustment means may be employed in order to adjust the length or width of the frame. An adjustment to the length or width of the frame would necessarily adjust the tension of the fabric 12 stretched about the frame. FIGS. 6 and 6A show the male/female engagement with a manual tensioning mechanism built in. Inside the female section 100 is a shoulder 102 with an engagement hole 104 in the center welded to the inside diameter of the tube. At the end of the male tube 200, a nut 202 is welded in and a long threaded socket set screw 204 with an engaging point 206 is threaded into this nut 202. A bead of weld 208 or screw or limit pin is then applied to the socket set screw through an access hole (not shown). The male and female sections are now engaged as shown in FIG. 6. Then, an allen wrench 300, or the like, may be inserted through the tool hole 210 to engage the socket set screw 204. The allen wrench may be turned clockwise to extend the screw, thus forcing the male section partially out of the female section. When the bead of weld 208 contacts the backside of the nut 202, it prevents further extension of the screw and the consequent travel of the male section, as shown in FIG. 6A. Another bead of weld 34 (or other limiting means such as a limiting screw or limit pin) may be used to prevent the screw from being removed from the nut 202. This limited travel mechanism allows a reasonable amount of engagement between the male/female tube sections to offer stability to the assembly.

[0036] A folding mechanism is used to facilitate the positioning of the movable frame in either the vertical position or the horizontal position. Conventional folding mechanisms are well known in the art, and it is to be understood that any suitable folding mechanism may be employed.

[0037] One embodiment of the base member 38 is shown in FIG. 7. This embodiment of the base member 38 is used in conjunction with the embodiments shown in FIGS. 3A, 5A and 5B. FIG. 8 shows a side view along the line 8-8 in FIG. 7, illustrating a leg 40 of the armrest 42 on the base in combination with the crossbar 44 and the ledge 46. The ledges 46 are affixed to each leg 40 of the base member 38 and are used to support the fixed frame of the seat at all times, as well as the movable frame when it is placed in the horizontal position.

[0038]FIG. 9 shows the first embodiment of the present invention, having three longitudinal sleeves for receiving the longitudinal tubes of the frame members. Transverse hems are also provided for receiving transverse tubes of the frame members. This embodiment is preferred when the intent is to eliminate the mattress or other cushioning material. Longitudinal portions of fixed frame member 8 and movable frame member 10 are bend down and back respectively, as shown, away from the fabric plane at a sufficient distance to reduce the likelihood of contact with an occupant sitting or lying on the fabric 12. The straight tube 6 is also lowered below fixed frame member 8, and below the fabric plane at a sufficient distance therefrom to reduce the likelihood of contact with an occupant sitting or lying on fabric 12. In this embodiment, the fabric is oreinted such that the direction of primary stretch is parallel to the longitudinal portion of the frame members, and the fabric is stretched by means of the mechanism shown in FIGS. 6, 6A & 4B.

[0039]FIG. 9A shows the second embodiment of the present invention, having only two longitudinal hems in the fabric for receiving the remote longitudinal frame members. The middle cross bar 6 is positioned above the fabric 12, as shown.

[0040] The embodiments described herein allow the futon to be shipped directly to the consumer in a disassembled or partially disassembled state, which decreases the cost of shipping. Because the design of the present invention obviates the need for support slats and cushions or a mattress, the weight and volume of the product is greatly reduced, which also decreases the cost of manufacture and shipping. Further, assembly and disassembly requires only a minimal amount of basic tools, allowing a consumer to receive the disassembled apparatus and easily assemble it. If the fabric 12 becomes soiled, frayed, cut, or otherwise mutilated, or if the styles and personal tastes of the consumers change, the consumer may easily remove the fabric 12 for cleaning, repair, or replacement. Also, the frame may be quickly disassembled for transport. If the fabric 12 becomes loose after extended use, the adjustment means may be employed to retain the tension necessary for comfortable use.

[0041] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, other sizes and shapes of frame members could be used. Multiple panels of fabric may be used, and other adjustment means could be employed to adjust the size of the frame members and thus the tension of the fabric. Other methods and means of attaching the fabric to the frame may be employed. Another type of stretchable fabric may be utilized in place of the polyester elastomeric fabric, such as a rubber webbing. Even a non-stretchable fabric may be used. Further, the apparatus and method disclosed and claimed herein may be used in a variety of different furniture or seating applications, including adjustable and non-adjustable sofas, chairs, lounge chairs, car bench seats or car seats. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. 

What is claimed is:
 1. An adjustable seating apparatus comprising: a substantially rectangular first frame having a pair of longitudinal members and a pair of transverse members; a substantially rectangular second frame having a pair of longitudinal members and a pair of transverse members, said second frame pivotally attached to said first frame along a longitudinal side thereof so that said second frame may be positioned between a substantially horizontal and a substantially vertical position; a fabric stretched across both said first and second frames; and a base frame attached to said first frame for disposing said first frame in a generally horizontal orientation.
 2. The structure set forth in claim 1, wherein said fabric has elastomeric qualities.
 3. The structure set forth in claim 1, wherein said fabric includes a hem along each longitudinal side thereof, and wherein each said longitudinal frame member is disposed within a corresponding longitudinally disposed fabric hem.
 4. The structure set forth in claim 3, wherein said fabric also includes a hem along each transverse side thereof, and wherein each said transverse frame member is disposed within a corresponding transversely disposed fabric hem.
 5. The structure set forth in claim 1, further including securing means for locking said second frame member into either a substantially horizontal position, or a position substantially perpendicular to said first frame.
 6. The structure set forth in claim 1, wherein said first and second frame members are adjustable in a transverse direction, allowing tension on said fabric to be adjusted in a transverse direction.
 7. The structure set forth in claim 4, wherein said first and second frame members are adjustable in the longitudinal direction, allowing tension on said fabric to be adjusted in a longitudinal direction.
 8. An adjustable seating apparatus comprising: a generally rectangular, horizontally oriented first frame member having a pair of longitudinal portions connected to a pair of transverse portions; a U-shaped frame member pivotally connected to each end of one of said longitudinal portions of said first frame member; a continuous fabric attached to both longitudinal portions of said first frame member, and also attached to a longitudinal portion of said U-shaped frame member; and a base member attached to said first frame for supporting said first frame in an elevated, generally horizontal position.
 9. The structure set forth in claim 8, wherein said fabric has elastomeric qualities.
 10. The structure set forth in claim 8, wherein said fabric includes a hem along each longitudinal side thereof, and a centrally positioned, longitudinally disposed hem on an underside thereof, wherein said longitudinal frame portions of said first frame and said U-shaped frame are disposed within said longitudinally disposed fabric hems.
 11. The structure set forth in claim 10, wherein said fabric also includes a hem along each transverse side thereof, and wherein said transverse portions of said first frame member and said U-shaped frame member are disposed within said transversely disposed fabric hems.
 12. The structure set forth in claim 8, further including securing means for locking said U-shaped frame member into either a substantially horizontal position, or a position substantially perpendicular to said first frame.
 13. The structure set forth in claim 8, wherein said first frame and said U-shaped frame are adjustable in a transverse direction, allowing tension on said fabric to be adjusted in a transverse direction.
 14. The structure set forth in claim 11, wherein said first frame and said U-shaped frame are adjustable in the longitudinal direction, allowing tension on said fabric to be adjusted in a longitudinal direction.
 15. A method of attaching a fabric material to a rigid frame, said method comprising the steps of: providing a pair of U-shaped frame members in pivotal relation, each having two transverse sides and one longitudinal portion therebetween; positioning said U-shaped frame members perpendicularly with respect to each other; attaching a fabric material to said longitudinal portions of each said U-shaped frame member; positioning said U-shaped frame members in a horizontal plane with each other; positioning a straight tube member above said fabric in a longitudinal direction; and attaching each end of said straight tube member to the point of attachment between said U-shaped members, so that when said U-shaped members are placed in a perpendicular position, said straight tube causes said fabric to assume a similar perpendicular position.
 16. A method of attaching a fabric material to a rigid futon frame, said method comprising the steps of: providing a pair of U-shaped frame members in pivotal relation, each having two transverse sides and one longitudinal portion therebetween; positioning said U-shaped frame members perpendicularly with respect to each other; attaching a fabric material to said longitudinal portions of each said U-shaped frame member; attaching a straight tube member to a central portion of said fabric on an underside thereof, running between and parallel to said longitudinal portions of said U-shaped members; and attaching each end of said straight tube member to the point of attachment between said U-shaped members, so that when said U-shaped members are raised to a perpendicular position, said straight tube causes said fabric to assume a similar perpendicular position. 